Samson TROVIS 5724-8 Service manual

Translation of original instructions
EB 5724-8 EN
Firmware version 2.12
Edition March 2023
TROVIS5724-8 (without fail-safe action)
TROVIS5725-8 (with fail-safe action)
Electric Actuators with Process Controller
For heating and cooling applications

Definition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
EB 5724-8 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 5724-8 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-5
1.2 Notes on possible personal injury ................................................................1-5
1.3 Notes on possible property damage.............................................................1-6
2 Markings on the device ..............................................................................2-1
2.1 Nameplate.................................................................................................2-1
2.2 Device code................................................................................................2-2
2.3 Firmware versions.......................................................................................2-3
3 Design and principle of operation ...............................................................3-1
3.1 Fail-safe action ...........................................................................................3-1
3.2 Communication ..........................................................................................3-2
3.3 Versions .....................................................................................................3-3
3.4 Additional equipment..................................................................................3-4
3.5 Technical data ............................................................................................3-5
3.6 Dimensions.................................................................................................3-7
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removing the packaging from the actuator ...................................................4-1
4.3 Transporting the actuator.............................................................................4-1
4.4 Lifting the actuator ......................................................................................4-1
4.5 Storing the actuator.....................................................................................4-1
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-1
5.3 Aligning the travel indication scale...............................................................5-2
5.4 Mounting the actuator .................................................................................5-2
5.4.1 TROVIS5724-8(force-lockingattachment) ...................................................5-3
5.4.2 TROVIS5724-8(form-tattachment)............................................................5-4
5.4.3 TROVIS5725-8(force-lockingattachment) ...................................................5-4
5.4.4 TROVIS5725-8(form-tattachment)............................................................5-4
5.5 Installing the control valve into the pipeline ...................................................5-5
5.6 Installing the accessories..............................................................................5-5
5.7 Electrical connection....................................................................................5-5
5.7.1 Establishing connection with the control station..............................................5-8
6 Operation..................................................................................................6-1
6.1 Device overview and operating controls........................................................6-1
6.2 Display ......................................................................................................6-2

Contents
EB 5724-8 EN
6.2.1 Readings and their meaning........................................................................6-2
6.3 Operating keys...........................................................................................6-3
6.4 Travel indicator...........................................................................................6-4
6.5 Interface.....................................................................................................6-4
6.5.1 Establishing connection with TROVIS-VIEW...................................................6-5
7 Start-up and conguration..........................................................................7-1
7.1 Initializing the actuator................................................................................7-1
7.2 Zero calibration ..........................................................................................7-1
7.3 Communication ..........................................................................................7-1
7.3.1 Protocol......................................................................................................7-3
7.3.2 Modbus parameters....................................................................................7-3
7.4 Conguringtheactuator..............................................................................7-4
7.5 Quick check ...............................................................................................7-4
8 Operation..................................................................................................8-1
8.1 Adjustingthesetpoint.................................................................................8-1
8.2 Starting/endclosed-loopoperation..............................................................8-2
8.3 Increasing/decreasingthesetpoint ..............................................................8-2
8.4 Selectingtheexternal/internalsetpoint ........................................................8-3
8.5 Startandstopprogramcontroller.................................................................8-3
8.6 Manualoverride.........................................................................................8-4
8.6.1 Manuallychangingthestemposition............................................................8-4
8.7 Changingmanual/automaticmodeandsettingmanualpositioningvalue .......8-5
8.7.1 Changingovertomanualmodeonthedevice...............................................8-5
8.7.2 ChangingtomanualmodeoverModbus ......................................................8-5
9 Malfunctions ..............................................................................................9-1
9.1 Troubleshooting ..........................................................................................9-1
9.2 Error messages...........................................................................................9-2
9.2.1 Error messages on the display......................................................................9-2
9.2.2 Modbus error .............................................................................................9-3
9.3 Emergency action .......................................................................................9-4
10 Servicing..................................................................................................10-1
11 Decommissioning .....................................................................................11-1
12 Removal ..................................................................................................12-1
12.1 Removing TROVIS5724-8.........................................................................12-1
12.2 Removing TROVIS5725-8.........................................................................12-1

Contents
EB 5724-8 EN
13 Repairs ....................................................................................................13-1
13.1 Returning the actuator to SAMSON............................................................13-1
14 Disposal...................................................................................................14-1
15 Certicates...............................................................................................15-1
16 Annex A ..................................................................................................16-1
16.1 Congurationandparameterlist................................................................16-1
16.2 ExcerptfromModbuslist .........................................................................16-11
16.3 Defaultsettingsandcustomer-specicdata ...............................................16-16
17 Annex B...................................................................................................17-1
17.1 Accessories ..............................................................................................17-1
17.2 After-sales service.....................................................................................17-2

EB 5724-8 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheTROVIS5724-8andTROVIS5725-8ElectricActuatorswithProcessControllerarea
combination of an electric actuator and an integrated digital controller with two PID control
modules. They are designed for operating a mounted globe valve. In combination with the
valve,theactuatorisusedtocontroltheowofliquidsorvaporsinthepipeline.Theelectric
actuators with process controller are suitable for closed-loop operation in heating and cool-
ing applications.
Theelectricactuatorwithprocesscontrollerisdesignedtooperateunderexactlydenedcon-
ditions (e.g. thrust, travel). Therefore, operators must ensure that the electric actuator with
processcontrollerisonlyusedinoperatingconditionsthatmeetthespecicationsusedfor
sizing it at the ordering stage. In case operators intend to use the electric actuator with pro-
cesscontrollerinapplicationsorconditionsotherthanthosespecied,contactSAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
viceforitsintendedpurposeorfordamagecausedbyexternalforcesoranyotherexternal
factors.
ÎRefertothetechnicaldataforlimitsandeldsofapplicationaswellaspossibleuses.See
the 'Design and principle of operation' section.
Reasonably foreseeable misuse
The electric actuators with process controller are not suitable for the following applications:
− Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
− Outdoor use
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performing service and repair work not described
Qualications of operating personnel
The electric actuators with process controller must be mounted, started up, serviced and re-
pairedbyfullytrainedandqualiedpersonnelonly;theacceptedindustrycodesandprac-
tices are to be observed. According to these mounting and operating instructions, trained
personnel refers to individuals who are able to judge the work they are assigned to and rec-
ognizepossiblehazardsduetotheirspecializedtraining,theirknowledgeandexperienceas
well as their knowledge of the applicable standards.

1-2 EB 5724-8 EN
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of electric actuators with
process controller. Work on the control valve may be necessary when mounting or removing
the device.
ÎObservetherequirementsforpersonalprotectiveequipmentspeciedinthevalvedocu-
mentation.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions,conversionsorothermodicationsoftheproductarenotauthorizedbySAMSON.
Theyareperformedattheuser'sownriskandmayleadtosafetyhazards,forexample.Fur-
thermore, the product may no longer meet the requirements for its intended use.
Safety features
Thefollowingsafetyfeaturesexist:
− The limit switches switch off the motor in the end positions.
− Anactiveblockingprotection(A8.3congurationitem=1,seeAnnexA)intheelectric
actuator with process controller prevents the valve from seizing up.
− Uponsupplyvoltagefailure,theTROVIS5725-8ElectricActuatorwithProcessController
causes the valve to move to a certain fail-safe position. The fail-safe action of SAMSON
actuatorsisspeciedontheactuatornameplate.
Warning against residual hazards
Theelectricactuatorwithprocesscontrollerhasadirectinuenceonthevalvewhenitis
mounted on the valve. To avoid personal injury or property damage, plant operators and
operating personnel must prevent hazards that could be caused in the control valve by the
process medium, the operating pressure, the signal pressure or by moving parts by taking
appropriate precautions. Plant operators and operating personnel must observe all hazard
statements, warnings and caution notes in these mounting and operating instructions, espe-
cially for installation, start-up and service work.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions as well as the refer-
enced documents to the operating personnel and to instruct them in proper operation. Fur-
thermore,operatorsmustensurethatoperatingpersonnelorthirdpartiesarenotexposedto
any danger.

EB 5724-8 EN 1-3
Safety instructions and measures
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthereferenceddocumentsandobservethespeciedhazardstatements,warnings
and caution notes. Furthermore, operating personnel must be familiar with the applicable
health, safety and accident prevention regulations and comply with them.
Referenced standards, directives and regulations
DeviceswithaCEmarkingfullltherequirementsofthefollowingDirectives:
− 2014/30/EU
− 2014/35/EU
− 2011/65/EU
DeviceswithanEACmarkingfullltherequirementsofthefollowingRegulations:
− TRCU004/2011
− TRCU020/2011
ThedeclarationsofconformityandtheTRCUcerticatecanbefoundinthe'Certicates'
section of these mounting and operating instructions.
The electric actuators with process controller are designed for use in low-voltage installations.
ÎFor wiring, maintenance and repair, observe the relevant safety regulations.

1-4 EB 5724-8 EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− CongurationManualforTROVIS5724-8andTROVIS5725-8ElectricActuatorswith
Process Controller uKH5724-8
− Mounting and operating instructions of the valve on which the electric actuator with pro-
cess controller is mounted, e.g. for SAMSON valves:
uEB5861forType3260Three-wayValve
uEB5863forType3226Three-wayValve
uEB5866forType3222GlobeValve
uEB5867forType3222NGlobeValve
uEB5868forType3213andType3214GlobeValves
uEB8111forType3321GlobeValve
uEB8113forType3323Three-wayValve
uEB8131forType3531GlobeValveforHeatTransferOil
uEB8135forType3535Three-wayValveforHeatTransferOil
uEB3018forType42-36EPressure-independentControlValve(PICV)withelectric
actuator

EB 5724-8 EN 1-5
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to electric shock.
ÎBeforeconnectingwiringandperforminganyworkonthedevice,disconnectthe
supply voltage and protect it against unintentional reconnection.
ÎOnly use power interruption devices that can be protected against unintentional re-
connection of the power supply.
ÎDo not open the back housing cover.
Theelectricactuatorswithprocesscontrollerareprotectedagainstspraywater(IP54).
ÎAvoid jets of water.
The switching output may be live after the supply voltage has been connected.
ÎDo not touch the wire ends of the switching output.
ÎWhen the switching output is not used, deactivate it in function M4 ('None' setting
uKH5724-8).
1.2 Notes on possible personal injury
WARNING
!
Crush hazard arising from moving parts.
Theform-tversionoftheelectricactuatorswithprocesscontrollercontainsmoving
parts(actuatorandplugstems),whichcaninjurehandsorngersifinsertedintothe
actuator.
ÎDonotinserthandsorngerintotheyokewhilethevalveisinoperation.
ÎDisconnect the supply voltage before performing any work on the control valve.
ÎDo not impede the movement of the actuator or plug stem by inserting objects into
their path.

1-6 EB 5724-8 EN
Safety instructions and measures
WARNING
!
Risk of personal injury due to incorrect operation, use or installation as a result of
information on the electric actuator with process controller being illegible.
Over time, markings, labels and nameplates on the electric actuator with process con-
troller may become covered with dirt or become illegible in some other way. As a re-
sult, hazards may go unnoticed and the necessary instructions not followed. There is a
risk of personal injury.
ÎKeepallrelevantmarkingsandinscriptionsonthedeviceinaconstantlylegible
state.
ÎImmediately renew damaged, missing or incorrect nameplates or labels.
1.3 Notes on possible property damage
NOTICE
!
Risk of actuator damage due to the supply voltage exceeding the permissible toler-
ances.
The actuator is designed for use according to regulations for low-voltage installations.
ÎObserve the permissible tolerances of the supply voltage.
Risk of actuator damage due to incorrect wiring of the inputs.
Incorrectwiringoftheinputsmayleadtoexcessivelyhighvoltagesanddamagethe
electric actuator with process controller.
ÎWire the inputs range according to the technical data.
Risk of actuator damage due to excessively high tightening torques.
The connection of the electric actuator with process controller must be tightened with
certaintorques.Excessivetighteningtorquesleadtopartswearingoutmorequickly.
ÎObservethespeciedtighteningtorques.
Risk of damage to the actuator by moving the actuator stem too far.
The actuator stem of the electric actuators with process controller can be adjusted manu-
ally.
ÎMove the actuator stem only as far as the bottom or top end position.

EB 5724-8 EN 1-7
Safety instructions and measures
NOTICE
!
The display does not work due to an interrupted cable connection.
The cable connection for the display is located underneath the front housing cover.
ÎOnly open the front housing cover to perform actions described in these instructions.
ÎDo not disconnect the connecting cable between the electric actuator and housing
cover.
Malfunction due to a conguration that does not meet the requirements of the appli-
cation.
Theelectricactuatorwithprocesscontrollerisconguredforthespecicapplicationby
settingcongurationitemsandparameters.
ÎPerformthecongurationforthespecicapplicationduringstart-upandafterare-
set to default settings.
Risk of damage to the screw heads on the front cover due to the use of the wrong
tool.
The actuator housing cover is fastened using TORX PLUS®screws, size 10IP.
ÎTo loosen and tighten the screws, only use the following screwdrivers:
− TORX®T10
− TORX PLUS®10IP
− Flat-bladescrewdriverwith0.8mmbladethicknessand4.0mmbladewidth
Risk of actuator damage due to direct contact with steam.
ÎDuring mounting, make sure that the actuator cannot come into contact with a jet of
steam during operation.

1-8 EB 5724-8 EN

EB 5724-8 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
The nameplate shown was up to date at the time of publication of this document. The name-
plate on the device may differ from the one shown.
12
15
14
2
3
45
6
7
11
8
910
13
1
1 Type designation
2DataMatrixcode
3 Material number
4 Serial number
5 Date of manufacture
6Supplyvoltage;powerlinefrequency
7 Power consumption
8Thrust (actuator stem retracts)
9Thrust(actuatorstemextends)
10 Fail-safe action
Extends
11 Rated travel
12 Stroking speed
13 Firmware version
14 DIN test with register number (only
versionwith"actuatorstemextends"
fail-safe action)
15 Other mark of conformity

2-2 EB 5724-8 EN
Markings on the device
2.2 Device code
Electric Actuator with Process Controller TROVIS572 x- 8 x x
Fail-safe action
Without 4
With 5
Ratedtravel/adaptation
6mm/forcelocking 1
12mm/forcelocking 2
15mm/form-t 3
Stem movement
Standard 0

EB 5724-8 EN 2-3
Markings on the device
2.3 Firmware versions
Firmware revisions
Old New
2.00 2.01
Communication parameters that cannot be changed are hidden.
2.01 2.10
Automatic protocol detection works with SSP and Modbus. In this case, Modbus is re-
strictedtothesetting'9600,8N1'.
The 'Communication module' and 'Protocol' communication parameters have been re-
placed by the communication parameter with same name (i.e. 'Protocol' but with different
setting options. The new settings are 'None', 'Automatic (SSP, Modbus)' and 'Modbus
(adjustable)'. 'Automatic (SSP, Modbus)' is set by default.
The message 'Last positioning value upon signal failure' has been replaced by 'Last
travel value'. The electric actuator with process controller stops immediately upon signal
failure with this setting.
Transit time measurement and initialization can be canceled by pressing the [0] key. The
electric actuator with process controller does not perform a zero calibration after cancel-
lation.Theactuatormovestoapredenedpositioningvalue.
2.10 2.11
Newsystemcodenumbers:2,38and58
'LIM1','LIM2','[I]/[O]keysorLIM1'and'[I]/[O]keysor LIM2' have been added to the
Trigger function (A1.5).
The error message 'Eb' is displayed at the actuator when a bus failure is detected.
Baudrate38400isnolongeravailableforModbus.
2.11 2.12
The system code numbers are assigned in the range from 0 to 99.

2-4 EB 5724-8 EN

EB 5724-8 EN 3-1
Design and principle of operation
3 Design and principle of
operation
TheTROVIS5724-8andTROVIS5725-8
Electric Actuators with Process Controller
contain two integrated digital controllers, re-
ferredtoascontroller[1]andcontroller[2]
inthefollowing.TheTROVIS5724-8iswith-
outfail-safeactionandtheTROVIS5725-8
has fail-safe action.
The electric actuators with process controller
are mounted onto SAMSONTypes3222,
3213,3214,2488,42-36E,3226and
3260 Valves as well as Series V2001 Valves
uptovalvesizeDN50.
Design
The actuator contains a reversible synchro-
nous motor and a maintenance-free gear.
The force of the motor is transmitted to the
actuator stem via gearing and cam disk.
Whentheactuatorstemextends,itpushes
against the valve's plug stem. When the ac-
tuator stem retracts, the return spring in the
valve causes the plug stem to follow the
movement (force-locking connection). The
valve and actuator have a force-locking con-
nection.Aform-tconnectionisusedfor
special valve models, e.g. Series V2001
valves.
The user can read and change the set point
and operating values at the control panel.
All other parameters can be changed in the
TROVIS-VIEW software. Modbus is used for
dataexchangebetweentheactuatorand
computer.
Fig.3-1: TROVIS5724-8 Electric Actuator with
Process Controller
Manual override
ÎSee the 'Operation' section.
The actuator version without fail-safe action
(TROVIS5724-8)hasahandwheelusedto
manually position the valve (only when the
electric actuator is disconnected from the
supply voltage). Travel and direction of ac-
tion can be read off the travel indication
scale.
3.1 Fail-safe action
TheTROVIS5725-8ElectricActuatorwith
Process Controller contains a spring mecha-
nism and an electromagnet. The actuator
stem is moved by the force of the spring to
the fail-safe position (lower end position)
when the electromagnet (connected to termi-
nals L and N) is de-energized.

3-2 EB 5724-8 EN
Design and principle of operation
The actuator stem of the TROVIS5724-8
Electric Actuator with Process Controller re-
mains in its last position in the event of sup-
ply voltage failure.
Increased wear and shortened service life
of the electric actuator with process
controller.
ÎDo not use the fail-safe action to control
the valve position.
TheTROVIS5725-8ElectricActuatorwith
Process Controller does not have a hand-
wheel on the housing cover. Manual over-
ride is possible, after removing the front cov-
er,usinga4mmAllenkey.Theactuator
stem immediately moves again to its original
position after the Allen key is removed from
the actuating shaft.
Testing according to DINEN14597
TheTROVIS5725-8ElectricActuatorwith
Process Controller with fail-safe action "actu-
atorstemextends"istestedbytheGerman
technical surveillance association TÜV ac-
cordingtoDINEN14597incombination
with different SAMSON valves. The register
number is available on request.
Note
NOTICE
!
3.2 Communication
Interface
TheactuatoristtedwithanRS-485inter-
face. The data transfer uses an SSP or Mod-
bus RTU protocol.
ÎSupported Modbus functions (see An-
nexA)
The electric actuator with process controller
can be connected to a control station over
Modbusandcanbeconguredusing
TROVIS-VIEW. Various communications
protocol (SSP or Modbus RTU slave) and a
bus connecting cable are used for various
functions.SeeAnnexA.
Conguration
The electric actuator with process controller
isconguredusingtheTROVIS-VIEWsoft-
warethatenablestheusertoeasilycong-
ure the controller as well as view process pa-
rameters online.
TROVIS-VIEW can be downloaded free of
charge from our website at
uwww.samsongroup.com > SERVICE &
SUPPORT > Downloads > TROVIS-VIEW.
Further information on TROVIS-VIEW (e.g.
system requirements) is available on our
website and in the Data Sheet uT6661 as
well as the Operating Instructions
uEB6661.
Note